Flaw detector for electrical conductors



-18, 1938" E. A. SPERRY, JR. ET AL 2,133 725 FLAW DETECTOR FOR ELECTRICAL CONDUCTORS Filed Feb. 12, 1952 2 Sheets-Sheet 1 -nmm s y INVENTORS v [:2 M 4. spam): .ze. FRA/VC HENRY 57/51 421; .m

I l w B Oct. 18 1938.

E. A. SPERRY, JR.. Er AL Filed Feb. 12, 1932 FLAW DETECTOR FOR ELECTRICAL CONDUCTOR'S 2 Sheets-Sheet. 2

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Patented Oct. 18, 1938 UNITED STATES PATENT OFFlC-E 'FLAW DETECTOR non ELECTRICAL coNDUorons Elmer A. Sperry, Jr., Brooklyn, and Francis Henry Shepard, Jr., New Rochelle, N. Y., assignors to Sperry Products, Inc.', Brooklyn, N. Y., a corporation of New York Application February 12, 1932, Serial N0. 592,52

14 Claims. (Cl. 175-18?) This invention relates to a method of and means for testing electrical conductors having surfaces of revolution, such as conical and cylindrical pipes, lead sheaths, shafts and the like, for surface and internal flaws.

It is now well known through Sperry Patents Nos. 1,804,380 and 1,820,505 that electrical con- "ductors can be tested for flaws by passing electric current therethrough and then detecting variations in the characteristics of current flow either by measuring the voltage drop due to increased resistance caused bya fiaw, or else exploring the electromagnetic field surrounding the conductor by means of'induction coils to detect any displacement of the current axis caused by a new. Difliculties arise, however, when it is attempted to apply these methods to testing cylindrical and conical objects such as lead sheaths or cables, pipes, and the like, wherein the entire circumference must be explored.

For this purpose, we propose to adapt the methods shown in the said patents to this particular use by causing the detector unit to travel in a spiral path' around the conductor. i'his may be accomplished by providing relative rotary as well as relative longitudinal or axial movement between the conductor being tested and the detector unit. The pitch of the spiral may 'be varied according to circumstances so that the entire surface may be tested by this-method of operation. 1

,- ing testing of the transformers, coils, or article being tested, or by the battery voltage drop. It is a further object of our invention, therefore, to provide an automatic sensitivity control for the amplifier which will eliminate from the detecting system all indications arising from changes in input not due to defects in the material being tested.

Inthe accompanying drawings, Fig. 1 is a side elevation of one form of our invention in which the conductor rotates while the detector unit travels axially or longitud nally.

Fig. 2 is-a viewsimilar to Fig. 1 of our invention applied to the testing of lead cables as they come from the cable-forming machine, the cable traveling axially or longitudinally while the detector unit is rotated.

Fig. 3 is a section taken on the line 3-3 of v Fig. 1 and showing the mounting for the current brush contacts.

Fig. 4 is an enlarged view, partly sectioned vertically of a form of energizing and detector 10 unit adapted especially for detecting transverse defects when the object under test is rotated.

' Fig. 5 is a view similar to Fig. \4 of a mechanism especially adapted for detecting mainly longitudinal defects.

. 15 Fig. 6 is a view similar to Figs. 4 and 5 showing a combination unit which is adapted for detecting either transverse or longitudinal defects.

Fig. 7 is a wiring diagram illustrating our 2 automatic sensitivity control.

Fig. 8 is a view similar to Fig. 2 but showin only the means for detecting principally longitudinal defects.

Fig. 9"is a view similar to Fig. 2 but showing only the means for detecting principally transverse defects.

Fig. 10 is a view similar to Fig. 9 showing the detector means applied to a conical surface.

Fig. 11 'is an elevation of a modified form of v the recording mechanism.

Fig. 12 is a view similar to Fig. 2 but showing another modification of our invention.

In thetFig." 1, form of the invention, a cable,

pipe, shaft or similar conductor to be tested is mounted in a machine I0 similar to a lathe having spindle blocks Ii and I2 for holding the conductor i3 in position for rotation. The rotation of the conductor may be accomplished by any suitable means such as motor through suitable gearing l6-l9.

The method offiaw detection employed here consists in sending current through the conductor and measuring the'variations in the charl5 operating acteristics of current flow caused by defects in said conductor. For energizing the conductor, we may provide, in one form of our invention, a pin-'- rality of contacts 20 pivotally supported in a frame 2| and pressed vby springs 22 into firm engagementwi th the cylindrical member at a plurality of points around its circumference in order to insure good contact. Said contacts 20 are connected through cables 23 to a generator (not shown) which supplies a current of preferin engagementwith the periphery of member it and spaced so as to measure the potential drop Y between two points along the axis of the conductor under test. Means are provided for moving the said pair of contacts axially of the member it while the latter is rotated so that a continuous spiral testing path is traced by said contacts on the periphery of member It. The rate of axial movement of contacts 25 will. of course, determine the pitch of the threads of the spiral and this pitch may. be varied in accordance with the type of defect one is seeking to detect. The axial movementof contacts 25 is provided by mounting said contacts in a support 8| which is carried on a guide-rod Ii. For eifecting movement of said support 80 and said contacts, a screw 32 is threaded through the support, and said screw may be rotated irom the same motor I! as'accomplishes the rotation of the test member it. -By this means, the support and contacts fl will be fed longitudinally of conductor ll.

'lhe spacing of the contact members 25 axially of the member under test is most efllcient' for the purpose of detecting mainly transverse flaws (see Fig.4). If it is desired to detect mainly longitudinal fiaws, another set of contacts 28 spaced radially with respect to the test piece it (see Fig. 5) may be provided. In this case, current issupplied to the test piece it preferably by an induction coil 50..-

stood that the variations in the characteristics of current fiow may be detected by induction coils, as shown in said Patent No. 1,820,505. Thus, in. Fig. 12 I have shown the set of contacts I! replaced by a pair of opposed induction coils 21 and the set of contacts it replaced by a pair of opposed induction coils it, said pairs of inductidn coils being arranged so that the axes of one ,pair'are at right angles to the axes of the other pair. This arrangement of coils enables the detection of variations in fiux in two planes. namely, the plane of fiux set up by the current contacts 2|! which is at right angles to the plane of fiux set up by the induction coil Iii.

In testing conical objects (see Fig. 10) the current could be supplied by contact members It and the induction coil would not be present.

.The contacts 25 would be carried'by a bar I0 (see Fig. 2) pivoted on a bracket Ii fixed to post iii. Said bar is spring-pressed by spring It so as to maintain contacts 25 continually in engagement with the conical surface it" being tested regardless of the varying diameter of the latter.

The small potential picked up by the contacts as or as may be amplified by the amplifier so,

the output of which may control a relay I.

- When a fiaw is encountered, the potential drop v increases sufilciently so that when amplified by .able integrally with the cylinder.

with a chart 44 on a rotating cylinder ll. Said relay and pen may be fed axially along said cylinder ll by means of a guide rod I on which said relay and pen unit is supported and by means of a screw 41 extending through said unit. Said screw 41 and said cylinder 48 may be rotated from the motor I! by suitable gearing as shown. The pen thustraces a spiral line on the chart 44 which corresponds to the spiral path travelled by the contacts on the member I! under test. When the chart u is. taken 08 the cylinder there is a developed picture of the condition ofthe member II.

If this is not desired, there may be employed a tape form of recorder which moves continuously beneath the pen 8 and any fiaws will be indicated by a notch in the continuous line similar to those made on the chart I.

In Fig. 2 we'have illustrated a modification of our invention wherein the member under test travels axially or longitudinally while the detecting unit is rotated. The contacts describe thesame spiral path, therefore, relative to the conductor under test, as in the Fig. 1 form wherein the cylindrical member under test was rotated and the contacts moved axially. In this case, the invention is shown as applied to the testing oi lead cables I! as said cables emerge from the cable-forming machine li.- Said cables travel at a substantially constant speed out of said machine and over a supporting pulley 52 after which they are wound upon the well known large reels. .The current may be put into said cable for testing purposes by means of contacts 20' which are slidably mounted in a block and are pressed into engagement with the cable by means of springs It. In this case, also, energization may be accomplished by means of an induction coil 50. The set of contacts Il may be employed alone, as shown in Fig. 9, or the contacts 28 may be employed alone, as shown in Fig. 8, or they may both be mounted for use, as shown in Fig. 2, in exactly the same manner as hereinbefore described in connection with the Fig. i 1

device.

For rotating thedetecting unit. we may provide a cylinder CI to which is fixed said contacts 25 and 26, the said cylinder being mounted on bearing rollers if supported in abase 0!. The said cylinder Ii may be rotated by being driven from any suitable driving means through such driving connection as belt 84 and pulley mov- The connections from the contacts 2| and It to the amplifier are made by means of leads (not shown) adapted to extend through a conduit it in said cylinder 8| to slip rings, 61 so that the potential diiference may be taken oil by brushes and conducted to the amplifier fit.

By reference to Fig. 'I it will be apparent that the output actuates the pen togive an indication of fiaw in response to the E. M. F.'s impressed on the input side of the amplifier. Such input variations may be due not only to variations in the characteristics of current fiow as hereinbefore described, but also to such factors as heating of the transformer, which energizes coil 50, heating of the coil iii or the lead sheath being tested, or the output may be varied by variations in amplification due to battery voltage drop and.

many other factors. We provide means whereby the pen will be actuated only in response to input due to variations in the characteristics of current fiow and not to any of the other factors mentioned. In this connection, it may be pointed out that the variations in input due to variations in the characteristics of current flow are of very short duration,. in fact, almost instantaneous,-

while the variations in input due to any of the other factors mentioned are of relatively long duration.

We therefore modify the amplifying system as by tapping the negative side of the output and causing such negative potential to be varied by means of the potentiometer P and the rate of current flow to be cut down by means of a resistance R and caused to charge a condenser C. The condenser C is connected to the grid of one of the tubes to place a negative bias thereon to vary the amplification factor of the tube. Because oi the potentiometer P, resistance R and condenser C it will be seen that a time lag is introduced because a negative potential can be placed upon the grid of the tube only to the extent that the condenser is being charged. Therefore, variations in the input due to such factors as heating of the transformer, coil, or

' the object being tested, which extend over a relatively long period of time will cause a negative bias to be built up on the grid which will vary the amplification of the tube, and therefore of the set, to compensate for the input variations which such factors introduce. A variation in input due to a flaw, however, lasts for only a,

relatively brief period of time and the output of such a brief period will not be of sufllclent duration to cause appreciable charging of condenser C and hence placing of a negative potential on the grid so that there is no measurable counteracting of the input due to flaws. In this manner. we are able to distinguish between variations of input due to flaws and variations ofinput due to c any other factor, such/as those hereinbefore enumerated. It will also correct for the changing current density in various parts of the object under test in the case where such object is conical.

The correcting mechanism described above may be put into or out of operation by means vides means in the full line position for tappinga relatively large negative potential but in the dotted line position taps a much smaller potential by reason ofthe shunt ground connection I02 including the resistance R.

In accordance with the provisions of the patent statutes, we have herein described the principle and operation. of our invention, together with the apparatus which we now consider to represent the best embodiment thereof, but we desire to have it understood that the apparatus shown is only illustrative and that the invention can be carried out by other means. Also, while it is designed to use the various features and elements in the combination and relations described, some i of these may be altered and others omitted withtively rotating said conductor and detector means. and means for simultaneously relatively moving said conductor and detector means axially.

2. In a flaw detector apparatus for electrical conductors, means for continuously passing current through said conductor, detector means in-' cluding a plurality of radially spaced contacts for detecting variations in the characteristics of current flow caused by flaws, means for relativelyrotating said conductor and detector means, and means for simultaneously relatively moving said conductor and detector means axially.

3. In a flaw detector apparatus for electrical conductors, means for continuously passing current through said conductor, detector means including a plurality of contacts, certain of said contacts being spaced axially and certain of said contacts being spaced radially, for detecting variations in the characteristics of current flow caused by flaws, means for relatively rotating said conductor and detector means, and means for simultaneously relatively moving said conductor and detector means axially.

4. In a flaw detector apparatus for electrical conductors, means for feeding said conductor axially, means for continuously energizing successive portions of said conductor by passing current therethrough, means for detecting variations in the characteristics ofcurrent flow caused by flaws, and means for continuously rotating said detector means around the energized portion of said conductor.

5. In a flaw detector apparatus for an electrical conductor having a surface of revolution of varying diameters, means for continuously energizing a portion of said conductor by passing current therethrough, means for detecting variations in the characteristics of current flow caused by flaws, means for causing said detecting means to travel in a spiral path around said conductor, and means whereby said detecting means adjusts itself in accord with the variations in diameter of said conductor.

6."In a flaw detector apparatus for an electrical conductor having a surface of revolution of varying diameters, means for continuously energizing a portion of said conductor by passing current therethrough, means for detecting variations in the characteristics of current fiowcaused by flaws, means for relatively rotating saidconductor and detecting means, means for simultaneously relatively moving said conductor and detecting means axially and means whereby said detecting means adjusts itself in accord with the variations in diameter of said conductor.

7. In a ilaw detector apparatus for electrical conductors having surfaces of revolution, means for continuously passing current through said conductor, detector means for detecting variations in the characteristics of current flow caused by flaws, means for amplifying said variations, and means whereby said amplifying means is rendered responsive only to, input of the type due to said variations.'

8. In a flaw detector apparatus for electrical conductors having surfaces of revolution, means for continuously passing current through said conductor, detector means for detecting variations in the characteristics of current flow caused by flaws, means for amplifying said variations, said variations being of'the short-period type of input, and means whereby said amplifying means is rendered responsive only to short-period: input.

9. In a flaw detector apparatus for electrical conductors having surfaces of revolution, means for continuously current through said conductor, detector means for detecting Variations in the characteristics of current flow caused by flaws, means for amplifying said variations including a plurality of amplifying tubes, and

means whereby said amplifying means is rendered responsive only to input of the type due to said variations, said last-named means including means connecting the output of said amplifying means with said tubes for impressing a bias on said tubes for neutralizing the input of other types of variations.

11. In a flaw detector apparatus for electrical conductors having surfaces of revolution. means for continuously passing current-through said conductor, detector means for detecting variations in the characteristics of current flow caused by flaws, means for amplifying said variations,

. said variations being of the short-period type of input, and means whereby said amplifying means is rendered responsive only to, short-period input, said last-named means including'means area? i whose operation is a function of the time for impressing a bias on said tubes for neutralising is rendered responsive only to short-period input,

said last-named means comprising means including a condenser for impressing a bias on said tubes for neutralizing the long-period type of input.

13. In a flaw detector apparatus for an electrical conductor having a surface of revolution, means for continuously energizing a portion of said conductor by passing current therethrough. means for detecting. variations in the characteristics of current flow caused by flaws, means for relatively rotating said conductor and detecting means and means for simultaneously relatively moving said conductor and detecting means axially.

14. The method of detecting defects in a metallic object, which consists in successively passing fluxes in different directions and in diflerent planes through the same portion of the object and in comparing quantities responsive to change in the fluxes. 

